Method of making flexible hard surfaced covering



30, 1933. c. F. HUMPHRl-:Ys

METHOD OF MAKING FLEXIBLE HARD SURFACED COVERING Filed May 16, 1929 2 Sheets-Sheet 1 NN in 1 illlwl) INVENTOR May 30, 1933 c. F. HUMPHREYS 1,911,364

FACED GOVERING METHOD OF MAKING FLEXIBLE HARD SUR Filed May 16, 1929 2 Sheets-Sheet 2 Patented May 30, 1933 I UNITED STATES PATENT; OFFICE t l' CHARLES F. HMPHREYS,;OF LANCASTER, PENNSYLVANIA, ASSIGNOR TO ARMSTRONG" CORK COMPANY, 0F` LANCASTER, PENNSYLVANIA, A CORPCBATION 0F PENNSYL- VANIA f `ntia'rrron or MAKING ELEXBLE HARD vsUnrAeEn (Jorritsmal i .Application filed May 16, 1929. Serial Nb. 363,581;`

Thisinvention relates to the manufacture of flexible hard surfaced coverings, and is herein particularly described as applied to the manufacture ofinlaid linoleum. It provides a method whereby a'wide variety of patterns can be reproduced at low cost.

There are two general methods of making inlaid linoleum. In one of themv the linoleum mix, in granular form, is applied through stencils to the burlap back so as to make up the desired pattern, the'mix then being consolidated under a press. In the other method, pattern elements are die-cut from sheets of linoleum mix and are applied to a backing.u This lattermethod is adaptable to continuous machine production, and a rotary type of machine for carrying out such process is well known in the art. i

Machines ofthe rotary type are very expensive and must be operated continuously and at relatively high speed to be economically justifiable'.- Unfortunately such machines, as heretofore constructed, have l,only been capable of `producing linoleums in a limited ield. `lhile it is possible' to vary the patterns by changing'the die rolls employed, the machineV as now constructed" are capable of applying only a relatively small number of colors. This limitation is a serious one because the trend'- is toward linoleums employing a variety of colors and particularly to linoleums having ha hazard contrasting spots of color embodied) in the design. 'f The rotary machine consists essentially of a large drum which carries the backing or web to which the pattern elements are to be applied. These pattern elements are cut out of unbacked sheets or webs of linoleum mix by means of die rolls which lie substantially tangent to the first mentioned roll. Each die roll must'be supplied with a web of linoleum mix which is as wide as the product of the machine. 'p

Each die roll is eifective for cutting up this web into small ieces. Those pieces which form no part` o? the final design are knocked out as scrap and the remaining pieces are applied by the die roll 'to the backing. Thereinust be a separate die'roll for each Vcolor of material employed. It follows that'ii three colors are employed., the amount of` scrap isftwice the area of the goods, and if four colors are employed, the amount of 'scrap is Ethree times the area of the goods. The amount of scrap may bey expressed by the following formula:

Scrap =Area ofV product (N l), where N equals the number of colors employed. Sometimes this lscrap may begmilled and used over again, but, particularly inthe lighter colors and in the marbles and jasps, itis'ditlicult if" not impossible to use the scrap because of the diiiiculty of controlling color.' f

From the foregoing it is clear that the ordinary rotary'machine is inherently of such character that designs employing small relatively `widely spaced spots ofcolorcannot be economically `produced thereon. `It is, however, highly desirable to produce linoleum'of this characterxat the .speeds which are obtainable only by the? rotary machine. I provide for applying pattern elements by the die rolls to a portion onlyof the web or backing. -Therefore, when the'mate'rial leaves the drum of the machine, art of the web is exposed. Some or all oft e exposed parts maybe filled in by handso as to provide brightly colored lspots,"or, ifdesired,

theyV may be left uncovered,thus providing a linoleum having portions at' different surface levels. i The pattern on linoleums made by vrotary machines usually repeats Vitself every 18 inches. The circumference of the die rolls employed is usually "54 inches and eachv die roll, as is well known, isprovided with scrap ejectors which areactuatedpby scrap rolls lying within thedie rolls. yThe size of the scrap roll is usually such that it makes three revolutions for each revolution of the die roll, thus giving the repeat length of onevthird of flinches, or 18 inches. While in certain of those cases where contrasting spots of color are tobe filled in by handit brought home very forcefully to the observer by the presence of the bright spots.

I therefore provide for applying to some of the recurrent uncovered web areas elements which merge into the general background of the design, and apply the contrasting design elements at intervals which are a multiple of the repeat length of the general pattern. This is highly advantageous las it has the effect of multiplying by several times the repeat length of the pattern, thus materially improving its appearance and sales value. For example, every third uncovered area may be filled with a pattern element of contrasting 'color and the two intermediate areas may be filled` with colors corresponding to colors applied by one or more of the die rolls.

/ After the design-,elements have been filled in by handthe-material is calendered, thus consolidating all of thepattern or design elements with the web and with one another.

If desired, the pattern elements may be left spaced apart so as to expose portions of the background. This is yparticularly effective in those patterns which are made in imitationfof tiling. In such cases the webis made Tof a color to simulate ymortar joints and the applied pattern elements `are made of a shape and color tocorrespond to tiles.

By the use of my process a pattern element simulating a brightly colored tile may be dropped inat such intervals as are designed. This relievesthe monotonyl of the goods and materially improves its salability.'

If desired, the design elements which are applied may belaid on over elements which have been applied by the machine. This is very advantageous in the production of special patterns.

My process involves relatively little expense because in the operation of a rotary machine there are alwaysl a number ,of inspectors .who check up on the material as it leaves the rotary machine proper and before it passes to the calender. These inspectors can l,fill in those areas which have been left exposed by the machine itself.

Int-he accompanying drawings illustrating-the present preferred embodiment of the invention and certain modifications thereof,

Figure l is a diagrammatic view illustrating the rotary machine,

Figure 2 is a top plan view of a part of a length of linoleum in process of manufacture and embodyingmy invention,

Figure3 is a section through a piece of linoleum made according to my invention, and ofthe type wherein a portion of the base material is exposed between pattern elements, and, Y

Figure 4 is a perspective view of still another form of linoleum, showing a pattern element applied over one which was applied to the base material by the machine.

.peripheral surface, which knives substantially cut through the web lLas it passes'between the die roll and the platen'rol1-7, sok

that the entire web is cut up into pieces.

As is also well understood in this art, the excess material is ejected by means of a scrap roll 8, lyingwithin the die roll and provided with pins which actuate strippers in the die roll. These strippers normally lie below the level of the cutting edges of the die rroll knives, but when engaged by the pins of the scrap roll 8 they are pushed outwardly to eject the scrap material into a trough or conveyor 9, by which the scrap is taken away from the machine. Brushes 8a engage the material as itis pushed outwardly by the strippersand aid in removing the scrap Vfrom the die roll. y

Upon continued rotation of the die roll 3, the remaining pieces of the web 4 are pressed outwardly by a pattern roll v(not shown) working on the strippers of the die roll, so that said remaining pieces are ap# plied to a webl0 of base material extending around the drum 2. The web l0 usually consists of a burlap backing covered bya linoleum mix of such character that it is somewhat tacky` whereby the pattern elements readily4 adhereto it. v l

, Each die roll 3 is effective for supplying a different color of linoleum tothe web and;

as above stated, in the rotary machines as heretofore employed, the entire surface of the webvhas been covered. According to the present invention, however, portionsjof the web are left uncovered. This is shown, in a conventional tile pattern, at the left hand side of Figure 2. The backing material is indicated at 10 and the general pattern` isV made up of squares lying side by side. -The squares are shaded in dotted lines and, as shown by this shading, the general pattern is made up of three colors, the different colors being applied by the three different die rolls shown in Figure l. The scrap rolls. are arranged to eject scrap material in such manner that squares 1l are left uncovered,

the web l0 showing through.

As the material leaves the drum 2 it passes over an inspection table l2 where the squares ll are filled in.A This work is done by in spectors or other workers standing along,- side the table l2. `They will employ .previously died-out squaresof material and fill in the squares 1l as the linoleum moves past. The pattern shown in Figure 2 is made up of 3 inch squares, so that the openings ll recr at? 18' inch intervals. I Thisfas kabove stated, is the normal-pattern repeat distance oncommercial rotary machines.`

At the Iright hand side of Figure 2 there is :shown the linoleum with the squares` 11; entirely filled in. The heavily shaded squares represent pattern element-s of contrasting color. It will be noted that one of such squares, numbered 13, has been used to fill in one of the squares 11 and that two squares 14ofcolors corresponding to colors applied by the die rolls have been filled in the next twoy squares 11. `These squares 14 merge into the general background and are not distinguishable from the squares which were applied bythe machine. The squares 14 arein' turn followedby a squarelof. contrasting color. In Figure 2 the squares 13` and 15 have been cross-hatched so as 4to showthem as differentfrom one another in color, and it will be understood that in this way many desirable effects may be obtained.

Figure 3 shows a linoleum comprising a burlap back 16 covered by a linoleum mix- 17, the backing 16 and the mix 17 forming the base web, and pattern elements 18 applied to thisfweb. The pattern elements 1S arespacedapart as shown in the drawings so as toleave parts ofthe web showing through. This is particularly desirable in those patterns =made in simulation of tile.V I have indicated at 19 a pattern element of contrasting color which is to be laid in by hand.

:From the foregoing it will be seen that l discharge an amount of scrap greater than the area of the product timesy one less than the number of active die rolls.

In Figure 4 I have shown a linoleum of the same general character as that illustrated in Figure 3, except that one of the pattern elements 18 has had laid upon it a pattern element 20, which, as hereinafter described, is consolidated with the pattern element 18 so as to form an integral part of the linoleum.

After the squares have all been filled in (in a linoleum of the type shown in Figure 2), or after the overlying design elements have been applied (as in the case of the linoleums shown in Figures 3 and 4), the material passes to a calender. This calender consists of a main roll 21 having a blanket 22 extending around a portion of the circumf'erence thereof. The blanket 22 is backed by pressure rollers 23 and the linoleum passes between the blanket and the drum 21 where the several parts are compressed and consolidated. After leaving the calender the product goes to the stove for curing in the usual way.

My pending application Serial No. 361,- 095, filed May 7, 1929, relates to a surface covering having pattern elements arrangedk to provide a repeating pattern and other elements'` arrangedA at intervals -which "are a multiplie of the repeat lengthof the general pattern. `The broad invention of applytion of John Emig, Serial No. 361,076,filed y May 7 1929, now Patent 1,824,041.

A machine for automatically applying died-out `pattern elements tothe web in such manner that portions thereof vare exposed only at intervals which are a multiple of the repeat distance as determined by the' scrap roll, is described and claimed inthe pending application of John Wiley, Serial No. 365,- 625, filed May24, 1929, nowy Patent 1,873',- 090 issued Augustes, 1932. i i Y i I haveillustrated and described a present preferred embodiment 4of the invention and certain modifications thereof. Y It will be understood, however, that the invention .is not limited to these forms, nor-to the `precise method of manufacture described, as it may` be otherwise embodied or practicedl within the scope of the-following claims.A

I claim: p' 1 1. In the method of making 'a flexible lsurface `covering `having a base web with overlying design elements in a machine effective for cutting a web of facing material into pattern elements andV scrap,.-discharg ing the scrap andapplying the'several pattern elements to` the base, the steps consisting in covering a portion only of' the base web with said pattern elements and applying'fdesign-elementsto another portion of the base web by hand.

2. In the 'method' of makinga flexible surface covering having a baseweb with overlying design elements in a machine effective for cutting `-facing material into pattern elements and scrap, discharging thescrap, and applying the pattern elements to the base, the'steps consisting in discharging-the scrap in Asuch amount that portions of thebase web are unco-veredf'asthe materialleaves the machine.v

- 3. In the method of making a flexible surface covering havinga base web with overlying design elements in a machine effective y applying the'pattern elements to. the base, the steps -consisting in discharging an amount of scrap greater than the. area of the product times one less than the number of webs of facing material supplied to the machine, and applying the remaining material to the base web, thus forming a Inaterial wherein a portion of the web is uncovered.

5. In the method` of making a flexible surface covering having a base web with overlyingpattern elements in a machine effective for cutting a web or webs of facing ma- ,Y terial into pattern elements and scrap, discharging the scrap and applying the pattern elementsto the base, the steps consisting in discharging the scrap in such amount that the total area of the unscrapped material is less than the area of the goods, applying such unscrapped material to the web, thus leaving portions thereof uncovered, and subsequently applying pattern elements by hand to uncovered'portions of the web.

6.k In the method of making a flexible surface covering having` a base web with overlying pattern elementsV in a machine effective for cutting a web or webs of facing material into pattern elements and scrap, discharging the scrap and applying the pattern elements to the base, the steps consisting in discharging the scrap in such amount that the total area of the unscrapped material is less than the area of the goods, applying such unscrapped material to the web, thus leaving portions thereof imcovered, applying to certain of the uncovered portions pattern elements which merge with the general background of the design, and applying contrasting pattern'elements to other of said portions.

7. In ythemethod of making a iiexible surface covering having a base web with overlying pattern elements in a machine effective for cutting a web or webs of facing material into pattern elements and scrap,discharging the scrap and applying the pattern elements to the base, the steps consisting in discharging the scrap in such amount that the total area of the unscrapped material is less than the Yarea of the goods, applying such unscrapped material to the web, thus leaving portions thereof uncovered, applying to certain of the uncovered portions pattern elements which merge with the general background of the design, and applying contrasting pattern elelnents to other of said portions, the background elements and the contrasting elements being appliedl in sequence, whereby a pattern repeat which is a multiple of the distance between port-ions left uncovered is obtained.

8. In the method of making a flexible surface covering having a base web with overlying design elements, the steps vconsisting in forming a series of webs of facing materia-l,

each web being as wide as the desired product and the websbeing in different-i colors,

cutting the several webs into pieces, laying pieces from each web on a base webso as to form an overlying'pattern thereon, and dis-` charging the remainder ofthe webs as scrap, the total area of thev pieces from the several webs applied to the base web being less than the area of such base web whereby a portion of the ,base web is left uncovered.

9. In tlie method of making a iexible surface covering having a base web with overlying design elements, the steps consisting in forming a series of webs of facing nia-l terial, cutting the several webs into pieces, laying pieces from each web -on a base webso as to form an overlying pattern thereon, and limitingthe number of pieces so supplied as to leave a portion of the base web uncovered, discharging the remainder of the webs as scrap.

l0. In the method of making a Hexible surface covering having a base Yweb with overlying design elements, thev stepsconsist-l ing in forming a base web having a facing of .linoleum composition, forming a series of webs of facing material, each web being substantially as wide as the'base web, cutting the several webs of the series .into pieces, and laying pieces from each web on portions only of the base web so as to form an overlying pattern thereon, the facing of the base web being exposed between overlying pattern elements. K. f

In testimony whereof I have hereunto set my hand.

CHARLES F. HUMPI-IREYS.

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